MecSoft's RhinoCAM Software Review, Pt 3

5-axis Continuous Machining is a new set of operations in RhinoCAM
2012 that gives the programmer the complete control over machining
complex parts on 5-axis machines. This is a key functionality today that
was missing from previous versions of RhinoCAM, a big limitation.

Curve Projection Machining projects curves onto one or
more surfaces.

Figure 37: 5-axis curve
projection machining

Between Curves Machining machines surfaces or solids
defined between two curves. Those who work with 5-axis machines (I
include myself) know how much this is needed.

Figure 38: 5-axis between-curves
machining

Flow Curve Machining follows a curve laying on the drive
surface

Figure 39: 5-axis flow curve
machining

Surface Normal Machining machines surfaces or solids in
parallel planes using the surface normal vectors for tool
orientation; very useful in geometries like blades.

Figure 40: 5-axis surface-normal
machining

Swarf Machining machines walls using the sides of the
cutter while riding one or more bottom surfaces, for geometry like
that in the following image

Machine Operation Options

The option group maintains the same VisualMILL structure that is similar
for all these machine operation types, with a main folder (specifying the
name of the operation, as defined by the user) and the following subfolders:

Machine Features defines the area to be machined in the
operation through the regions and start points.

Tool defines the tool, which can be input from the
predefined library. I found the generation process simple, and
similar to that many popular CAM or simulators. It is possible to
load and save libraries of tools.

Figure 43: Tool creation and
selection

Feed and Speeds dialog has all the necessary parameters
and options to define the spindle speed and direction; feed rates
can be defined by values or else loaded from the tool or from a
file.

Figure 44: Feeds and speeds
dialog box

Clearance Geometry defines the clearance plane, which can
be set easily using different references, including the automatic
one. The cut transfer method can be defined by this clearance plane,
and it is an interesting alternative to the skim clearance (distance
from maximum part point).

Figure 45: Clearance options

Parameters specifies correct and optimal strategies for
machining operations. These are essential, because RhinoCAM makes
available a variety of parameters that control the way to cut the
material, depending on the type of operation (2- or 5-axis, for
example). At times, however, I got the sense that there were too
many options which might confuse new users – as in VisualMILL. But
then I realized that both packages generally followed the same
logic, which requires you to acquire the necessary experience in any
CAM product.

Machine Operations Parameters

I won’t go into the details of all the parameters for the full range of
operations, but I would like to describe some of them (these are also found
in VisualMILL).

2.5-axis handles facing, pocketing, and profiling, and advanced
operations like roughing, finishing, and re-machining. On cut
parameters, I can define the cutting tolerance, direction, cut start
side with the option of outside/inside for close curves, and also
stepover control.

There is a complete set of parameters to control the cut levels
(rough or finish), and a very good entry and exit motions settings
(approach and retract). I want to highlight a folder dedicated to
advanced cut parameters in which users can control the cut corner
rounding, arc fitting, cut smooth transitions and bridges creation.

3-axis includes not only roughing and finishing methods, but also
advance machining strategies such as specialize finishing methods for
radius, spiral, and curve projection machining, and additional powerful
methods for complex shapes. With the cut parameters, it is possible to
control the Intol/Outtol and stock tolerances, the direction method
(mixed, climb, or conventional), complete cut levels settings, and a
good optimized machining with stepover and ramp control. As with
2.5-axis, there are also the entry and exit motion settings.

5-axes contains roughing and finishing mufti-axis operations. In
this case, the cut parameters are very comprehensive, stressing cut
pattern (parallel to X, Y, Z, or specified by the user), traversal
cutting (one way or zig-zag), stepover, and the necessary control of the
tool axis (lead/lag and tilt angles). Also, the cut levels control has
an understandable interface.

Regarding the management of entry/exit, there is a wide range of
options that cover the most common ways for tool input and output, as
well as transitions and connections.

Finally, I was happy to see the gouge check options, in which I could
perform gouge checks for tool geometry (holder, shaft, and tip) against
checked geometry, with the ability to detect collisions, and then decide
on the strategy within the predefined options.

Tool Path Simulation

As you may have noticed, I could write many pages describing the wide
range of options in this software, but I would not dare abuse your patience
as a reader. Thus I will stop hereto briefly describe simulation methods.

RhinoCAM has different ways to run simulations: it allows me to control
its speed, interrupts, toolpath step levels, and the stock's
representation/visibility with or without material removal. This is,
however, a neutral program code simulation, which means what I do not see
the actual Gcode the machine will receive.

Figure 46: Material removal
simulation inside RhinoCAM

I found a great option in advanced modules: the machine simulation is a
great help for programmers, especially in cases of position changes between
different operations. It can also be used for processes with 4- and 5-axis
functions. Again, the simulation is based on neutral code and not Gcode
program that the real CNC machine will receive; for this reason, the
simulation of the controller is not included in the virtual RhinoCAM
machine.

Figure 47: Machine simulation

Figure 48: Machine simulation
run on a different machine

Figure 49: Machine simulation
with program lines

Knowledge Bases

When I make many similar process, it’s possible to save and load
knowledge bases or K-Base. I can archive an entire sequence of operations
and all associated parameters to a knowledge database. After this, the
knowledge base can be loaded across other part files.

The default knowledge base allows me to set default parameters for
machining operations. This allows the reuse of the parameters without having
to enter the same parameters when creating new machining operations on same
part or new part files. All this saves my time!

Graphical Tool Path Editor

I end my review with the graphical tool path editor, because I see it as
very useful. It brings a lot of possibilities to experienced users.

Conclusion

RhinoCAM is a general-purpose 2- to 5-axis simultaneous CAM solution
especially targeted at SMEs (small and medium size enterprises) with a
desirable combination of features, affordable price, ease of learning, and
ease of use.

Despite all this, I would still like to see MecSoft work on (if they
aren’t already) adding modules for multitasking machines (single and
multi-turret and multi-Spindle), like Mazak’s Integrex series. These
complete all operations - turning, milling, boring, and drilling - in a
single setup. I’d also like to see a module dedicated to CNC wire-cut EDM
(electrical discharge machining) machines.

RhinoCAM 2012 provides all the benefits provided by the standalone
VisualMILL 2012 software, but has the added advantage of being able to work
directly and natively in the Rhino MCAD environment. The geometric
interaction results in time savings, eliminates the drawback of translation
formats, and reduces the learning curve.

As a fan of all areas in CAM, after trying RhinoCAM 2012, I can conclude
that it gave me a very positive feeling for the extensive technical
capabilities, as well as the ease of use and pleasant operation.

Additional Information

About the Author

Daniel Dobrzynski
is a expert in the CAD/CAM industry with over 27 years’
experience as enterprise consultant. He has worked as a
designer (mainly in automotive & aerospace areas of big
companies), CAM programmer, post processor generator,
advance machine builder for CAM simulation, PLM
administrator, methodology and procedures creator. He has
more than 20 years as a CAD/CAM/CAE certified trainer.
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